ESAB M3® Plasma G2 User manual

m3 G2 (ICH) Plasma System

Instruction Manual

0558011509 07/2014

(use with EPP-201/360/450/601 Power Sources)

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3

m3 G2 (ICH) Plasma System

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

CAUTION

Be sure this information reaches the operator.

You can get extra copies through your supplier.

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SAFETY

13

1.0 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize

precautionary information from the

references listed in Additional Safety

Information section. Before performing any instal-

lation or operating procedures, be sure to read and

follow the safety precautions listed below as well

as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions

can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure

skin and eyes. Hot metal can cause burns. Training

in the proper use of the processes and equipment

is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in

any work area, even if welding helmets, face

shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when oper-

ating or observing operations. Warn bystanders

not to watch the arc and not to expose themselves

to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess trousers, high-topped

shoes, and a welding helmet or cap for hair

protection, to protect against arc rays and hot

sparks or hot metal. A ameproof apron may also

be desirable as protection against radiated heat

and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars

should be kept buttoned, and open pockets

eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition

or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and

can y far. Bystanders should also wear goggles

over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a pro-

tective non-ammable covering. Combustible

materials include wood, cloth, sawdust, liquid

and gas fuels, solvents, paints and coatings,

paper, etc.

2. Hot sparks or hot metal can fall through cracks

or crevices in oors or wall openings and cause a

hidden smoldering re or res on the oor below.

Make certain that such openings are protected

from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until

the work piece has been completely cleaned so

that there are no substances on the work piece

which might produce ammable or toxic vapors.

Do not do hot work on closed containers. They

may explode.

4. Have re extinguishing equipment handy for

instant use, such as a garden hose, water pail,

sand bucket, or portable re extinguisher. Be

sure you are trained in its use.

5. Do not use equipment beyond its ratings. For

example, overloaded welding cable can overheat

and create a re hazard.

6. After completing operations, inspect the work

area to make certain there are no hot sparks or

hot metal which could cause a later re. Use re

watchers when necessary.

7. For additional information, refer to NFPA Stan-

dard 51B, "Fire Prevention in Use of Cutting and

Welding Processes", available from the National

Fire Protection Association, Battery march Park,

Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

SAFETY

14

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS — May be

dangerous. Electric current owing through any

conductor causes localized Electric

and Magnetic Fields (EMF). Weld-

ing and cutting current creates EMF

around welding cables and welding

machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

SAFETY

15

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases which con-

tain chemicals known to the State of California

to cause birth defects and, in some cases, can-

cer. (California Health & Safety Code §25249.5

et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or im-

properly maintained equipment can cause

injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more

information on safe practices for electric

arc welding and cutting equipment, ask

your supplier for a copy of "Precautions

and Safe Practices for Arc Welding, Cut-

ting and Gouging", Form 52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tung-

sten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting

and Allied Processes.

SAFETY

16

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not

intended to be used outside during precipitation unless sheltered.

Enclosure Class

This product is solely intended for plasma cutting. Any other use may

result in personal injury and / or equipment damage.

15°

Maximum

Tilt Allowed

CAUTION

If equipment is placed on a surface that slopes more

than 15°, toppling over may occur. Personal injury and

/ or signicant damage to equipment is possible.

CAUTION

To avoid personal injury and/or equipment damage,

lift using method and attachment points shown here.

CAUTION

Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your

safety is involved.

WARNING

DANGER

CAUTION

SAFETY

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SAFETY

23

1. Eorcez-vous de toujours coner les tâches d'installation,

de dépannage et d'entretien à un personnel qualié.

N'eectuez aucune réparation électrique à moins d'être

qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur

de la source d'alimentation, débranchez l'alimentation

électrique.

3. Maintenez les câbles, les ls de mise à la terre, les

branchements, le cordon d'alimentation et la source

d'alimentation en bon état. N'utilisez jamais un équipe-

ment s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez

l'équipement à l'écart de toute source de chaleur,

notamment des fours, de l'humidité, des aques d'eau,

de l'huile ou de la graisse, des atmosphères corrosives et

des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les

panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu

et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA

SÉCURITÉ -- Pour obtenir de l'information

supplémentaire sur les règles de sécurité à

observer pour l'équipement de soudage à

l'arc électrique et le coupage, demandez un exem-

plaire du livret "Precautions and Safe Practices for

Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman-

dées et mises à votre disposition par l'American Weld-

ing Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé

dans une opération de soudage ou de coupage,

dégage des vapeurs ou des gaz contenant des

chimiques considéres par l'état de la Californie

comme étant une cause des malformations

congénitales et dans certains cas, du cancer.

(California Health & Safety Code §25249.5 et

seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans

observer les précautions nécessaires,

peut produire des fissures et un

échappement dangereux des gaz.

Une brisure soudaine du cylindre, de la

soupape ou du dispositif de surpression peut causer

des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le

détendeur approprié conçu pour utilisation sur les cyl-

indres de gaz comprimé. N'utilisez jamais d'adaptateur.

Maintenez en bon état les tuyaux et les raccords. Observez

les instructions d'opération du fabricant pour assembler

le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l'aide

d'une chaîne ou une sangle, sur un chariot manuel, un

châssis de roulement, un banc, un mur, une colonne ou

un support convenable. Ne xez jamais un cylindre à un

poste de travail ou toute autre dispositif faisant partie

d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes

fermées. Si le détendeur n'est pas branché, assurez-vous

que le bouchon de protection de la soupape est bien en

place. Fixez et déplacez les cylindres à l'aide d'un chariot

manuel approprié. Toujours manipuler les cylindres avec

soin.

4. Placez les cylindres à une distance appropriée de toute

source de chaleur, des étincelles et des ammes. Ne jamais

amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez CGA

Standard P-1, "Precautions for Safe Handling of Com-

pressed Gases in Cylinders", mis à votre disposition par

le Compressed Gas Association, 1235 Jeerson Davis

Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-

ment entretenu de façon défectueuse ou

inadéquate peut causer des blessures

graves ou mortelles. Par conséquent :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tung-

sten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting

and Allied Processes.

SAFETY

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DESCRIPTION

26

ABBREVIATIONS:

m3 G2 - m3 Generation 2

A/C - Air Curtain

AHC - Automatic Height Control

ICH - Interface Control Hub

PGC - Plasma Gas Control

SGC - Shield Gas Control

WIC - Water Injection Control

Below are some abbreviations used throughout this manual.

DESCRIPTION

27

2.0 System Diagrams

The following pages illustrate dierent system congurations available on the m3 Generation 2 (m3 G2). With

this system, ESAB oers 8 dierent congurations to meet customer’s requirements. Below are the descriptions

of each conguration.

1. Base System

This system is the basic conguration for the m3 G2 Plasma System. It contains the major components, such as the

Power Supply (EPP201/360/450/601), Coolant Circulator, PT-36 Torch, Remote Arc Starter (RAS), Plasma Gas Control

(PGC), Shield Gas Control (SGC), and Interface Control Hub (ICH). This system will meet most customers’ needs in

cutting carbon steel, stainless steel, and aluminum. It also has the functionality of marking on carbon steel and

stainless steel with the same torch and the same consumables. By simply alternating cutting and marking mode on

the y, this system is capable of cutting and marking in the same part program without changing the consumables.

To use this system, customer CNC needs to send start signal and corner signal while in geometric corner; at the

same time, customer CNC needs to monitor the fault signal and motion enable signal from ICH. This base system

does not come with Automatic Height Control (AHC). Customer will have to provide AHC and control its sequence.

2. Base System + AHC

This system includes the Base System plus the ESAB AHC, called a “B4 lifter”. In this conguration, ICH will control

plasma sequence, and also the AHC sequence. Customer CNC needs to provide the start signal and corner signal

for normal cutting.

3. Base System + A/C

This system includes the above Base System and ESAB Air Curtain (A/C). Air Curtain is a device used to improve the

performance of plasma arc when cutting underwater. ICH from the Base System will control the sequence and turn

on/o the air.

4. Base System + WIC

This system is congured to introduce the Water Injection Control (WIC), a module used to regulate cut water ow

to shield the cutting process. This conguration is to meet needs of a customer who wants to cut stainless steel

without using H35. This system still uses the standard PT-36 torch, but a dierent set of consumables. Similar to the

dry system, this WIC system can also do marking with water shield.

5. Base System + AHC + WIC

This system provides customer the Base System, AHC (Automatic Height Control), and WIC (Water Injection

Control). With this system, customer needs only to provide start signal and corner signal for cutting stainless steel

with water injection.

6. Base System + AHC + A/C

This system gives the customer the ability to cut under water with ESAB Automatic Height Control (AHC).

7. Base System + WIC + A/C

This system is the Base System adding Water Injection Control (WIC) and Air Curtain (A/C). Customer needs to

provide their own Height Control and control its sequence.

8. Base System + AHC + WIC + A/C

This complete system gives the opportunity for customer to cut carbon steel, stainless steel, and aluminum with

ESAB Auto Height Control (AHC). Customer has the capability to cut stainless steel with the Water Injection Control

(WIC), and underwater with the help of Air Curtain (A/C).

DESCRIPTION

Base System

CC-IC

PS-IC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

PN 0558007515

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

Gas Controls Power Cable

SGC-CAN

SGC-A/C IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

CC

(Coolant Circulator)

PS

(Power Supply)

ICH

(Interface Control Hub)

PGC-PWR

Customer

CNC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System

ICH-IO

ICH-PWR

AHC-VDR

CUSTOMER

AHC

Base System + AHC

CC-IC

PS-IC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

PN 0558007515

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

Gas Controls Power Cable

SGC-CAN

SGC-A/C IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

CC

(Coolant Circulator)

PS

(Power Supply)

ICH

(Interface Control Hub)

PGC-PWR

Customer

CNC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

AHC

ICH-IO

ICH-PWR

RAS -VDR

AHC- AC IN

AHC-CAN

ICH-AC2

ICH-AHC CAN

AHC Power Cable

AHC-VDR

Base System + A/C

CC-IC

PS-IC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-A/C OUT

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

Air Curtain

Hose

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

PN 0558007515

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

Gas Controls Power Cable

SGC-CAN

SGC-A/C IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

CC

(Coolant Circulator)

PS

(Power Supply)

ICH

(Interface Control Hub)

PGC-PWR

Air Curtain

Customer

CNC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

A/C

ICH-IO

ICH-PWR

AHC-VDR

CUSTOMER

AHC

Base System + WIC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

WIC-H

2O

OUT

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

PN 0558007515

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

SGC-CAN

SGC-AC IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

PGC-PWR

Customer

CNC

BPR

(Back Pressure

Regulator)

WIC

(Water Injection

Control)

230V AC

Manual

0558009491

WIC-Air IN (optional)

WIC-H

2O IN

WIC-AC IN

WIC-CAN

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

ICH-IO

ICH-CAN

ICH-PWR IN

ICH

(Interface Control Hub)

AHC-VDR

CUSTOMER

AHC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

WIC

CC-IC

PS-IC

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

CC

(Coolant Circulator)

PS

(Power Supply)

Base System + AHC + WIC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

AHC- AC IN

AHC-CAN

WIC-H

2O

OUT

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

SGC-CAN

SGC-AC IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

PGC-PWR

Customer

CNC

AHC-VDR

BPR

(Back Pressure

Regulator)

WIC

(Water Injection

Control)

230V AC

WIC-Air IN (optional)

WIC-H

2O IN

WIC-AC IN

WIC-CAN

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-CAN

ICH-IO

ICH-PWR

ICH-AC2

ICH-AHC CAN

ICH-AC1

ICH

(Interface Control Hub)

CC-IC

PS-IC

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

PN 0558007515

CC

(Coolant Circulator)

PS

(Power Supply)

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

AHC + WIC

Base System + AHC + A/C

CC-IC

PS-IC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-A/C OUT

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

Air Curtain

Hose

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

PN 0558007515

ICH-RAS CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

Gas Controls Power Cable

SGC-CAN

SGC-A/C IN

CC-TC OUT

CC-TC IN

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

CC

(Coolant Circulator)

PS

(Power Supply)

ICH

(Interface Control Hub)

PGC-PWR

Air Curtain

Customer

CNC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

AHC + A/C

ICH-IO

ICH-PWR

RAS -VDR

AHC- AC IN

AHC-CAN

ICH-AC2

ICH-AHC CAN

AHC Power Cable

AHC-VDR

Base System + WIC + A/C

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-A/C OUT

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

WIC-H

2O

OUT

Air Curtain

Hose

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

PN 0558007515

ICH-RAS CAN

ICH-CAN

ICH-SGC CAN

IFH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

SGC-CAN

SGC-AC IN

SGC-A/C IN

CC-TC OUT

CC-TC IN

ICH-IO

ICH-PWR

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

ICH

(Interface Control Hub)

PGC-PWR

Air Curtain

Customer

CNC

BPR

(Back Pressure

Regulator)

WIC

(Water Injection

Control)

230V AC

WIC-Air IN (optional)

WIC-H

2O IN

WIC-AC IN

WIC-CAN

AHC-VDR

CUSTOMER

AHC

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

WIC + A/C

CC-IC

PS-IC

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

CC

(Coolant Circulator)

PS

(Power Supply)

Base System + AHC + WIC + A/C

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

RAS-TC IN

Air

N

2

O2

CH4

H35

Ar

SGC-A/C OUT

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

2

SGC-O2

SGC-CH4

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

AHC- AC IN

AHC-CAN

WIC-H

2O

OUT

Air Curtain

Hose

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

35

PGC-Ar

PGC-CAN

PN 0558007515

ICH-RAS CAN

ICH-AC2

ICH-AHC CAN

ICH-WIC CAN

ICH-SGC CAN

ICH-PGC CAN

ICH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

-)

RAS-PSC

PS-PA

PS-E(

-)

PS-PSC

Coolant Return Hose

SGC-CAN

SGC-AC IN

SGC-A/C IN

CC-TC OUT

CC-TC IN

ICH-IO

ICH-PWR

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

ICH

(Interface Control Hub)

PGC-PWR

Air Curtain

Customer

CNC

AHC-VDR

BPR

(Back Pressure

Regulator)

WIC

(Water Injection

Control)

230V AC

WIC-Air IN (optional)

WIC-H

2O IN

WIC-AC IN

WIC-CAN

R

m3 G2 Systems

Interconnect Diagram

BOLD FONT = Cable Connection Label

POWER

DATA

LIQUID

GAS

Optional

R

G2 Base System +

AHC + WIC + A/C

CC-IC

PS-IC

Manual # 0558007865 - Rev.0 1/2008



Service Manual

This manual provides service / troubleshooting

instructions for CC11 consoles beginning with

AORJ735024 models.

CC11

COOLANT

CIRCULATOR

CC

(Coolant Circulator)

PS

(Power Supply)

DESCRIPTION

36

2.1 Power Supply

The m3 G2 system can use dierent plasma power supplies. ESAB provides the EPP-201/360/450/601, with various input voltages and current

output for your requirements. For details about our power supplies, please refer to the power supply’s specic manual.

m3 Plasma Power Supply Input/Output Information

m3 201,

380 / 400V,

50 / 60Hz

m3 360,

380 / 400V,

50 / 60Hz

m3 450

380V

50/60HZ

380V TAPS

m3 450

380V

50/60HZ

400V TAPS

m3 450

400V

50/60HZ

m3 601

380V

50/60HZ

380V TAPS

m3 601

380V

50/60HZ

400V TAPS

m3 601

400V

50/60HZ

Input

Input Voltage (3-Phase) 380 / 400V 380 / 400V 380VAC 380VAC 400VAC 380VAC 380VAC 400VAC

Input Current (3-Phase) 60 / 57A RMS 140 / 132A RMS 167A RMS 167A RMS 159A RMS 217A RMS 217A RMS 206A RMS

Input Frequency 50 / 60 HZ 50 / 60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ

Input KVA 39.5 KVA 91.6 KVA 109.9 KVA 109.9 KVA 110.2 KVA 142.8 KVA 142.8 KVA 142.7 KVA

Input Power 35.5 KW 82.5 KW 98.9 KW 98.9 KW 99.1 KW 128.5 KW 128.5 KW 128.4 KW

Input Power Factor 90.0 % 90.0 % 90% 90% 90% 90% 90% 90%

Recommended Input

Power Cable

2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 4/0 AWG 4/0 AWG 4/0 AWG

Input Fuse (Recommended) 100A 200A 200A 200A 200A 250A 250A 250A

Output

Output Open Circuit Voltage

(OCV) (High Range Cutting)

360 VDC 360 VDC 430VDC 406VDC 427VDC 430VDC 406VDC 427VDC

Output Cutting Range

(100% Duty)

30A to 200A 30A to 360A 35A to 450A 35A to 600A

Output Marking Range

(100% Duty)

10A to 36A 10A to 36A 10A to 100A 10A to 100A

Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW

Protection Class IP 21 IP 21 IP 21 IP 21

Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm

Weight 493 kg 493 kg 850 kg 850 kg

380/400V Power Supplies

DESCRIPTION

37

m3 Plasma Power Supply Input/Output Information

m3 201

460V, 60Hz

m3 201

575V, 60Hz

m3 360

460V, 60Hz

m3 360

575V, 60Hz

m3 450

460V, 60HZ

m3 450

575V, 60HZ

m3 601

460V, 60HZ

m3 601

575V, 60HZ

Input

Input Voltage (3-Phase) 460V 575V 460V 575V 460VAC 575VAC 460VAC 575VAC

Input Current (3-Phase) 51A RMS 41A RMS 115A RMS 92A RMS 138A RMS 110A RMS 179A RMS 143A RMS

Input Frequency 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ

Input KVA 40.6 KVA 40.6 KVA 91.6 KVA 91.6 KVA 110.0 KVA 109.6 KVA 142.6 KVA 142.4 KVA

Input Power 35.5 KW 35.5 KW 82.5 KW 82.5 KW 99.0 KW 98.6 KW 128.4 KW 128.2 KW

Input Power Factor 90.0 % 90.0 % 90.0 % 90.0 % 90% 90% 90% 90%

Recommended Input

Power Cable

2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 1/0 AWG 2/0 AWG 1/0 AWG 1/0 AWG

Input Fuse (Recommended) 100A 60A 150A 125A 200A 150A 250A 200A

Output

Output Open Circuit Voltage

(OCV) (High Range Cutting)

360 VDC 360 VDC 431VDC 431VDC

Output Cutting Range

(100% Duty)

30A to 200A 30A to 360A 35A to 450A 35A to 600A

Output Marking Range

(100% Duty)

10A to 36A 10A to 36A 10A to 100A 10A to 100A

Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW

Protection Class IP 21 IP 21 IP 21 IP 21

Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm

Weight 493 kg 493 kg 850 kg 850 kg

460/575V Power Supplies

DESCRIPTION

38

2.2 Coolant Circulator (CC-11)

Specications

Dimensions: 34.00" (864 mm) high x 21.75" (552 mm) wide x 28.00 (711 mm) deep

Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)

Pump Type:

Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),

CW rotation as viewed from nameplate.

Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.

AC Input Voltages

50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power

200 / 230 / 400 / 460 / 575 V, + / - 10%

AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes

Pump Capacity

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

Cooling Capacity @ 1.60 gpm

(6.0 l/min)

16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)

at 45° F (25° C) temperature dierence between high coolant temperature and ambient air tem-

perature using ESAB coolant p/n 0558004297 (25% propylene glycol / 75% distilled water).

Max. Delivery Pressure 175 psig (12 bars)

Reservoir Capacity 4 gallons (15.2 liters)

The Coolant Circulator (CC-11) recirculates coolant to

cool the torch, electrode and nozzle. For more specif-

ic details, please refer to the CC-11 Instruction manual.

p/n 0558007515

DESCRIPTION

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